WO2005059150A2 - Procede de fermentation - Google Patents

Procede de fermentation Download PDF

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Publication number
WO2005059150A2
WO2005059150A2 PCT/US2004/041969 US2004041969W WO2005059150A2 WO 2005059150 A2 WO2005059150 A2 WO 2005059150A2 US 2004041969 W US2004041969 W US 2004041969W WO 2005059150 A2 WO2005059150 A2 WO 2005059150A2
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WO
WIPO (PCT)
Prior art keywords
fermentation
alpha
enzyme
amylase
carbohydrate
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PCT/US2004/041969
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English (en)
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WO2005059150A3 (fr
Inventor
Mads Torry Smith
Gregory Alan Crabb
John Francis Ress
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Novozymes North America, Inc
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Priority to US10/579,403 priority Critical patent/US20070082385A1/en
Publication of WO2005059150A2 publication Critical patent/WO2005059150A2/fr
Publication of WO2005059150A3 publication Critical patent/WO2005059150A3/fr

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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
    • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
    • C12P7/06—Ethanol, i.e. non-beverage
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/10—Biofuels, e.g. bio-diesel

Definitions

  • the present invention relates to enzymatic processes for producing fermentation products, wherein the fermenting organism performance during fermentation is improved and the yield is increased.
  • Fermentation processes are used for making a vast number of commercial products, including alcohols (e.g., ethanol, methanol, butanol); organic acids (e.g., citric acid, acetic acid, itaconic acid, lactic acid, gluconic acid); ketones (e.g., acetone); amino acids (e.g., glutamic acid); gases (e.g., H 2 and CO 2 ), and more complex compounds, including, for example, antibiotics (e.g., penicillin and tetracycline); enzymes; vitamins (e.g., riboflavin, B ⁇ 2 , beta-carotene); hormones, and other compounds which are difficult to produce synthetically.
  • alcohols e.g., ethanol, methanol, butanol
  • organic acids e.g., citric acid, acetic acid, itaconic acid, lactic acid, gluconic acid
  • ketones e.g., acetone
  • amino acids e.
  • Fermentation processes are also commonly used in the consumable alcohol (e.g., beer and wine), dairy (e.g., in the production of yogurt and cheese), leather, and tobacco industries. There is a need for further improvement of fermentation processes and for improving processes that include a fermentation step.
  • the present invention provides improved processes for producing a fermentation product.
  • the fermenting organism performance such as yeast performance, during fermentation is improved resulting in an increased fermentation product yield.
  • the present invention also provides improved processes for producing ethanol using one or more of the processes described herein.
  • the term "increased yield” means that the product yield provided by a process of the invention is higher compared to the yield of a corresponding process under the same conditions wherein the carbohydrate-source generating enzyme(s) is(are) added during the propagation of the fermenting organisms.
  • lag phase means the period preceding the exponential growth phase when cells may be metabolizing but are not yet growing.
  • growth means an increase in cell number.
  • the invention relates to a process of producing a fermentation product in a fermentation medium which process comprises a fermentation step, which fermentation step includes subjecting liquefied mash to a carbohydrate-source generating enzyme and a fermenting organism, wherein the process comprises: i) introducing the fermenting organism into the fermentation medium, ii) adding said carbohydrate-source generating enzyme after the lag phase of the fermenting organism, iii) fermenting under conditions suitable for producing the fermentation product.
  • the invention in a second aspect relates to a process for producing a fermentation product, especially ethanol, comprising (a) milling whole grains; (b) liquefying the product of step (a); (c) introducing the fermenting organism into the liquefied product obtained in step (b), (d) adding the carbohydrate-source generating enzyme after the lag phase of the fermenting organism, and (e) fermenting under conditions suitable for producing the desired fermentation product, especially ethanol.
  • Other fermentation products e.g., listed in the "Background"-section herein may also be produced this way.
  • the present invention provides improved processes for producing a fermentation product.
  • the fermenting organism including yeast, performance during fermentation is improved resulting in an increased fermentation product yield.
  • the present invention also provides improved processes for producing ethanol and other fermentation products using one or more of the processes described herein.
  • Fermentation Processes of the invention In the beginning of a SSF batch fermentation a lag phase is introduced when the batch is inoculated with a fermenting organism, such as yeast.
  • a carbohydrate-source generating enzyme such as glucoamylase
  • glucoamylase When a carbohydrate-source generating enzyme, such as glucoamylase, is dosed simultaneously with the yeast, buildup of substrate to high concentrations occurs.
  • the initially high sugar level induces stress which can possibly lead to increased glycerol formation (fermenting organism/yeast stress response).
  • the extra substrate used for the glycerol production is then lost for, e.g., ethanol formation.
  • the inventors have found that delayed addition of a carbohydrate-source generating enzyme to liquefied mash increases the product yield of a fermentation process.
  • the inventors have shown that delayed addition of glucoamylase to a corn mash fermentation results in an increased ethanol yield.
  • the increase in the fermentation product yield observed is believed to be due to the fermenting organism being allowed time to acclimatize initially before being subjected to a rapid sugar release resulting from addition of glucoamylase or another carbohydrate-source generating enzyme.
  • inhibition of the fermenting organism due to a substrate "shock" is eliminated or at least minimized.
  • the fermenting organism exit the initial lag phase before being subjected to high sugar levels.
  • the inventors found that the ethanol yield in a 65 hours corn mash batch fermentation was increased with a 3.5 hours delayed in addition of glucoamylase.
  • Another reason for the increase in production yield could be that the carbohydrate concentration available relative to the carbohydrate source demand of the fermenting organism is optimized by delaying the addition of the carbohydrate-source generating enzyme.
  • tailing is observed at the end of fermentation, so a delay in enzyme addition does not alter the fermentation time significantly.
  • a sugar peak higher than 150 g glucose/liter may be observed.
  • the delayed enzyme addition provides a higher yield at a standard enzyme dose.
  • the invention relates to a process of producing a fermentation product in a fermentation medium which process comprises a fermentation step, which fermentation step includes subjecting liquefied mash to a carbohydrate-source generating enzyme and a fermenting microorganism, wherein the process comprises: i) introducing the fermenting organism into the fermentation medium, ii) adding said carbohydrate-source generating enzyme after the lag phase of the fermenting organism.
  • the carbohydrate-source generating enzyme is added when the exponential growth phase of the fermenting organism is initiated.
  • Fermentation "Fermentation” refers to any fermentation method or process comprising a fermentation step.
  • a fermentation process of the invention includes, without limitation, fermentation methods or processes used to produce alcohols (e.g., ethanol, methanol, butanol); organic acids (e.g., citric acid, acetic acid, itaconic acid, lactic acid, gluconic acid); ketones (e.g., acetone); amino acids (e.g., glutamic acid); gases (e.g., H 2 and CO 2 ); antibiotics (e.g., penicillin and tetracycline); enzymes; vitamins (e.g., riboflavin, B 12 , beta- carotene); and hormones.
  • alcohols e.g., ethanol, methanol, butanol
  • organic acids e.g., citric acid, acetic acid, itaconic acid, lactic acid, gluconic acid
  • ketones e.g., acetone
  • amino acids e.g., glutamic acid
  • gases e.g., H 2 and CO
  • Fermentation processes also include fermentation processes used in the consumable alcohol industry (e.g., beer and wine), dairy industry (e.g., fermented dairy products), leather industry and tobacco industry.
  • Preferred fermentation processes include alcohol fermentation processes, as are well known in the art.
  • Preferred fermentation processes are anaerobic fermentation processes, as are well known in the art.
  • the process of the present invention is used in combination with a saccharification process, in which additional enzymatic activities, such as esterase, such as lipase and/or cutinase, phytase, laccase, cellulase, xylanase, alpha- amylase, glucoamylase, or mixtures thereof, may be used in processing the substrate, e.g., a starch substrate.
  • additional enzymatic activities such as esterase, such as lipase and/or cutinase, phytase, laccase, cellulase, xylanase, alpha- amylase, glucoamylase, or mixtures thereof, may be used in processing the substrate, e.g., a starch substrate.
  • the process of the invention is used in the production of ethanol.
  • Fermentation media refers to the environment in which the fermentation is carried out and which includes the fermentation substrate, that is, the carbohydrate source that is metabolized by the fermenting organism(s).
  • the fermentation media including fermentation substrate and other raw materials used in the fermentation process of the invention may be processed, e.g., by milling and liquefaction or other desired processes prior to the fermentation.
  • the fermentation medium can refer to the medium before or after the fermenting organism(s) is(are) added, such as, the medium in or resulting from a liquefaction step, as well as the media which comprises the fermenting organisms, such as, the media used in a simultaneous saccharification and fermentation process (SSF) .
  • SSF simultaneous saccharification and fermentation process
  • Fermenting organism refers to any organism, including bacterial and fungal organisms, suitable for use in a desired fermentation process. Especially suitable fermenting organisms according to the invention are able to ferment, i.e., convert, sugars, such as glucose or maltose, directly or indirectly into the desired fermentation product. Examples of fermenting organisms include fungal organisms, such as yeast. Preferred yeast includes strains of the Saccharomyces spp., and in particular, Saccharomyces cerevisiae.
  • yeast include, e.g., Red Star®/Lesaffre Ethanol Red (available from Red Star/Lesaffre, USA) FALI (available from Fleischmann's Yeast, a division of Burns Philp Food Inc., USA), SUPERSTART (available from Alltech), GERT STRAND (available from Gert Strand AB, Sweden) and FERMIOL (available from DSM Specialties).
  • Red Star®/Lesaffre Ethanol Red available from Red Star/Lesaffre, USA
  • FALI available from Fleischmann's Yeast, a division of Burns Philp Food Inc., USA
  • SUPERSTART available from Alltech
  • GERT STRAND available from Gert Strand AB, Sweden
  • FERMIOL available from DSM Specialties.
  • the substrate is generally selected based on the desired fermentation product and the process employed, as is well known in the art.
  • substrates suitable for use in the processes of present invention include starch-containing materials, such as tubers, roots, whole grains, corns, cobs, wheat, barley, rye, milo or cereals, sugar-containing raw materials, such as molasses, fruit materials, sugar, cane or sugar beet, potatoes, and cellulose-containing materials, such as wood or plant residues.
  • liquefied mash includes any of the above raw materials, which have been subjected to liquefaction using any method known in the art. Preferred is enzymatically liquefied mash, especially liquefied corn mash.
  • Carbohydrate-Source Generating Enzymes includes glucoamylases (being a glucose generators), and beta-amylases and maltogenic amylases (being maltose generators). Other enzymes producing other carbohydrates suitable for the fermenting organism in question is also contemplated according to the invention.
  • a carbohydrate- source generating enzyme is capable of providing energy to the fermenting organism(s) used in the process of the invention and/or may convert the carbohydrate in question directly or indirectly to the desired fermentation product, preferably ethanol.
  • the carbohydrate- source generating enzyme may be mixtures of enzymes falling within the definition.
  • glucoamylase especially an acid amylase, even more preferred a fungal acid alpha-amylase.
  • the ratio between fungal acid alpha-amylase activity (AFAU) per glucoamylase activity (AGU) (AFAU per AGU) may in one embodiment of the invention be at least 0.1, in particular at least 0.16, such as in the range from 0.12 to 0.50.
  • contemplated glucoamylases, alpha-amylases and beta-amylases are set forth in the sections below. It is to be understood that the enzymes used according to the invention should be added in effective amounts.
  • Glucoamylase A glucoamylase used according to the invention may be derived from any suitable source, e.g., derived from a micro-organism or a plant.
  • Preferred glucoamylases are of fungal or bacterial origin, selected from the group consisting of Aspergillus glucoamylases, in particular A. niger G ⁇ or G2 glucoamylase (Boel et al. (1984), EMBO J. 3 (5), p. 1097-1102), or variants thereof, such as disclosed in WO 92/00381 , WO 00/04136 add WO 01/04273 (from Novozymes, Denmark); the A.
  • awamori glucoamylase (WO 84/02921 ), A. oryzae (Agric. Biol. Chem. (1991 ), 55 (4), p. 941-949), or variants or fragments thereof.
  • Other Aspergillus glucoamylase variants include variants with enhanced thermal stability: G137A and G139A (Chen et al. (1996), Prot. Eng. 9, 499-505); D257E and D293E/Q (Chen et al. (1995), Prot. Engng. 8, 575-582); N182 (Chen et al. (1994), Biochem. J. 301 , 275-281 ); disulphide bonds, A246C (Fierobe et al.
  • glucoamylases include Corticium rolfsii glucoamylase (U.S. Patent No. 4,727,046), Talaromyces glucoamylases, in particular, derived from Talaromyces emersonii (WO 99/28448), Talaromyces leycettanus (U.S. Patent No. Re. 32,153), Talaromyces duponti, Talaromyces thermophilus (U.S. Patent No. 4,587,215).
  • Bacterial glucoamylases contemplated include glucoamylases from the genus Clostridium, in particular C. thermoamylolyticum (EP 135,138), and C. thermohydrosulf ⁇ ricum (WO 86/01831 ).
  • compositions comprising glucoamylase include AMG 200L; AMG 300 L; SANTM SUPER, SANTM EXTRA L, SPIRIZYMETM PLUS, SPIRIZYMETM FUEL, SPIRIZYMETM B4U and AMGTM E (from Novozymes A/S); OPTIDEXTM 300 (from Genencor Int.); AMIGASETM and AMIGASETM PLUS (from DSM); G-ZYMETM G900, G-ZYMETM and G990 ZR (from Genencor Int.).
  • Glucoamylases may in an embodiment be added in an amount of 0.02-20 AGU/g DS (Dry Solids), preferably 0.1-10 AGU/g DS, such as about 2 AGU/g DS.
  • Amylase According to the invention preferred alpha-amylases are of fungal or bacterial origin. More preferably, the alpha-amylase is a Bacillus alpha-amylase, such as, derived from a strain of B. licheniformis, B. amyloliquefaciens, B. stearothermophilus, and B. subtilis. Other alpha-amylases include alpha-amylase derived from a strain of Bacillus sp., including Bacillus sp.
  • alpha-amylases include alpha-amylases derived from a strain of Aspergillus, such as, Aspergillus oryzae and Aspergillus niger alpha-amylases.
  • the alpha-amylase is an acid alpha-amylase.
  • the acid alpha-amylase is a fungal acid alpha-amylase or a bacterial acid alpha- amylase. More preferably, the acid alpha-amylase is a fungal acid alpha-amylase derived from the genus Aspergillus. A commercially available acid fungal amylase is SP288 (available from Novozymes A/S, Denmark).
  • the alpha-amylase is an acid alpha-amylase.
  • the term "acid alpha-amylase" means an alpha-amylase (E.C.
  • a preferred fungal acid alpha-amylase is a Fungamyl-like alpha-amylase.
  • the term "Fungamyl-like alpha-amylase” indicates an alpha-amylase which exhibits a high homology (identity), i.e. more than 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85% 90%, 95%, 96%, 97%, 98%, or even 99%% homology (identity) to the amino acid sequence shown in SEQ ID NO: 10 in WO 96/23874.
  • fungal alpha-amylases When used as a maltose generating enzyme fungal alpha-amylases may be added in an amount of 0.001-1.0 AFAU/g DS, preferably from 0.002-0.5 AFAU/g DS, preferably 0.02-0.1 AFAU/g DS.
  • the alpha-amylase is an acid alpha-amylase, preferably from the genus Aspergillus, preferably of the species Aspergillus niger.
  • the acid fungal alpha-amylase is the one from A. niger disclosed as "AMYA_ASPNG" in the Swiss- prot/TeEMBL database under the primary accession no. P56271.
  • set acid fungal amylase having at least 70% identity, such as at least 80% or even at least 90%, 95%, 96%, 97%, 98%, or 99% identity thereto is contemplated.
  • a preferred acid alpha-amylase for use in the present invention may be derived from a strain of B. licheniformis, B. amyloliquefaciens, and ⁇ . stearothermophilus.
  • compositions comprising alpha-amylase include MYCOLASE from DSM (Gist Brocades), BANTM, TERMAMYLTM SC, FUNGAMYLTM, LIQUOZYMETM X and SANTM SUPER, SANTM EXTRA L (Novozymes A/S) and CLARASETM L-40,000, DEX- LOTM, SPEYME FRED, SPEZYMETM AA, and SPEZYMETM DELTA AA (Genencor Int.), and the acid fungal alpha-amylase sold under the trade name SP 288 (available from Novozymes A/S, Denmark).
  • the alpha-amylase may be added in an amount that is well- known in the art.
  • the acid alpha-amylase activity is preferably present in an amount of 5-50,0000 AAU/kg of DS, in an amount of 500-50,000 AAU/kg of DS, more preferably in an amount of 100-10,000 AAU/kg of DS, such as 500-1 ,000 AAU/kg DS.
  • Fungal acid alpha-amylase are preferably added in an amount of 10-10,000 AFAU/kg of DS, in an amount of 500-2,500 AFAU/kg of DS, more preferably in an amount of 100-1 ,000 AFAU/kg of DS, such as approximately 500 AFAU/kg DS.
  • the amylase may also be a maltogenic alpha-amylase.
  • a "maltogenic alpha- amylase” (glucan 1 ,4-alpha-maltohydrolase, E.C. 3.2.1.133) is able to hydrolyze amylose and amylopectin to maltose in the alpha-configuration.
  • a maltogenic alpha-amylase from Bacillus stearothermophilus strain NCIB 11837 is commercially available from Novozymes A/S.
  • Maltogenic alpha-amylases are described in EP patent no. 120,693, US Patent Nos. 4,598,048, 4,604,355 and 6,162,628, which are hereby incorporated by reference.
  • the maltogenic alpha-amylase is used in a raw starch hydrolysis process, as described, e.g., in WO 95/10627, which is hereby incorporated by reference.
  • Beta-amylase At least according to the invention a beta-amylase (E.C 3.2.1.2) is the name traditionally given to exo-acting maltogenic amylases, which catalyze the hydrolysis of 1 ,4- alpha-glucosidic linkages in amylose, amylopectin and related glucose polymers. Maltose units are successively removed from the non-reducing chain ends in a step-wise manner until the molecule is degraded or, in the case of amylopectin, until a branch point is reached. The maltose released has the beta anomeric configuration, hence the name beta-amylase. Beta-amylases have been isolated from various plants and microorganisms (W.M.
  • the fermentation process of the present invention is carried out as a simultaneous saccharification and fermentation step (SSF).
  • the fermentation process is used for producing an alcohol, preferably ethanol.
  • the presence of at least one carbohydrate-source generating enzyme may be used to raise the fermentation product yield, especially ethanol yield.
  • the fermentation is performed in the presence of one or more additional enzyme activities.
  • the additional enzyme(s) may be introduced prior to, during/simultaneous with or after addition of the carbohydrate-source generating enzyme.
  • esterase such as lipase, phospholipase and/or cutinase, phytase, laccase, protease, cellulase, cellobiase, and, or a mixture thereof.
  • one or more growth stimulators are added to further improve the fermentation, and in particular, the performance of the fermenting organism, such as, rate enhancement and product yield.
  • Preferred stimulators for growth include vitamins and minerals. Examples of vitamins include multivitamins, biotin, pantothenate, nicotinic acid, meso-inositol, thiamine, pyridoxine, para-aminobenzoic acid, folic acid, riboflavin, and Vitamins A, B, C, D, and E.
  • minerals include minerals and mineral salts that can supply nutrients comprising P, K, Mg, S, Ca, Fe, Zn, Mn, and Cu.
  • the enzymes may be derived or obtained from any origin, including, bacterial, fungal, yeast or mammalian origin.
  • the term "derived” means in this context that the enzyme may have been isolated from an organism where it is present natively, i.e. the identity of the amino acid sequence of the enzyme are identical to a native enzyme.
  • derived also means that the enzymes may have been produced recombinantly in a host organism, the recombinant produced enzyme having either an identity identical to a native enzyme or having a modified amino acid sequence, e.g., having one or more amino acids which are deleted, inserted and/or substituted, i.e., a recombinantly produced enzyme which is a mutant and/or a fragment of a native amino acid sequence or an enzyme produced by nucleic acid shuffling processes known in the art.
  • a native enzyme are included natural variants.
  • the term “derived” includes enzymes produced synthetically by, e.g., peptide synthesis.
  • the term “derived” also encompasses enzymes which have been modified e.g.
  • the term "obtained” in this context means that the enzyme has an amino acid sequence identical to a native enzyme.
  • the term encompasses an enzyme that has been isolated from an organism where it is present natively, or one in which it has been expressed recombinantly in the same type of organism or another, or enzymes produced synthetically by, e.g., peptide synthesis.
  • the terms "obtained” and “derived” refers to the identity of the enzyme and not the identity of the host organism in which it is produced recombinantly. The enzymes may also be purified.
  • the term “purified” as used herein covers enzymes free from other components from the organism from which it is derived.
  • the term “purified” also covers enzymes free from components from the native organism from which it is obtained.
  • the enzymes may be purified, with only minor amounts of other proteins being present.
  • the expression “other proteins” relate in particular to other enzymes.
  • the term “purified” as used herein also refers to removal of other components, particularly other proteins and most particularly other enzymes present in the cell of origin of the enzyme of the invention.
  • the enzyme may be "substantially pure,” that is, free from other components from the organism in which it is produced, that is, for example, a host organism for recombinantly produced enzymes.
  • the enzymes are at least 75% (w/w) pure, more preferably at least 80%, at least 85%, at least 90%, at least 95%, at least 96%, at least 97%, at least 98%, or at least 99% pure. In another preferred embodiment, the enzyme is 100% pure.
  • the enzymes used in the present invention may be in any form suitable for use in the processes described herein, such as e.g. in the form of a dry powder or granulate, a non- dusting granulate, a liquid, a stabilized liquid, or a protected enzyme. Granulates may be produced, e.g. as disclosed in US Patent Nos. 4,106,991 and US 4,661 ,452, and may optionally be coated by methods known in the art.
  • Liquid enzyme preparations may, for instance, be stabilized by adding stabilizers such as a sugar, a sugar alcohol or another polyol, lactic acid or another organic acid according to established methods.
  • stabilizers such as a sugar, a sugar alcohol or another polyol, lactic acid or another organic acid according to established methods.
  • Protected enzymes may be prepared according to the method disclosed in EP 238,216.
  • Production Processes A preferred application of the fermentation process of the invention described herein is in an ethanol production process (e.g., for use as a fuel or fuel additive). The processes described herein can be used to increase the rate and/or yield of ethanol production.
  • the invention relates to a process for producing a fermentation product, especially ethanol, comprising (a) milling whole grains; (b) liquefying the product of step (a); (c) introducing the fermenting organism into the liquefied product obtained in step (b), (d) adding the carbohydrate-source generating enzyme after the lag phase of the fermenting organism. (e) fermenting under conditions suitable for producing the fermentation product in question, especially ethanol.
  • the carbohydrate-source generating enzyme is added when the exponential growth phase of the fermenting organism is initiated.
  • Milling In the production of ethanol and other starch-based fermentation products according to the invention, the raw material, such as whole grain, preferably corn, is milled in order to open up the structure and allow for further processing.
  • Two processes are preferred according to the invention: wet milling and dry milling. Most used for ethanol production is dry milling where the whole kernel is milled and used in the remaining part of the process. Wet milling may also be used and gives a good separation of germ and meal (starch granules and protein) and is with a few exceptions applied at locations where there is a parallel production of syrups. Both wet and dry milling processes are well known in the art.
  • Liouefaction Fermentation product production processes such as ethanol production processes, generally involves the steps of liquefaction, saccharification, fermentation and optionally distillation.
  • milled gelatinized e.g., (whole) grain raw material is broken down (hydrolyzed) into maltodextrins (dextrins).
  • the hydrolysis may be carried out by acid treatment or enzymatically by alpha-amylase treatment, in particular with Bacillus alpha-amylases as will be described further below. Acid hydrolysis is used on a limited basis.
  • the raw material is in one preferred embodiment of a process of the invention milled whole grain. However, a side stream from starch processing may also be used.
  • Liquefaction is often carried out as a three-step hot slurry process.
  • the slurry is heated to between 60- 95°C, preferably 80-85°C, and the enzymes are added to initiate liquefaction (thinning).
  • the slurry is jet-cooked at a temperature between 95-140°C, preferably 105-125°C to complete gelatinization of the slurry.
  • the slurry is cooled to 60-95°C and more enzyme(s) is(are) added to finalize hydrolysis (secondary liquefaction).
  • the liquefaction process is usually carried out at pH 4.5-6.5, in particular at a pH between 5 and 6.
  • Milled and liquefied whole grains are known as mash.
  • the liquefaction process may be performed in the presence of an alpha-amylase.
  • Preferred alpha-amylases are of fungal or bacterial origin.
  • Bacillus alpha-amylases, variant and hybrids thereof, are specifically contemplated according to the invention.
  • Well-known alpha-amylases include alpha-amylase derived from a strain of B. licheniformis (commercially available as TERMAMYLTM from Novozymes A/S, Denmark), B. amyloliquefaciens, and ⁇ . stearothermophilus alpha-amylase (BSG).
  • alpha-amylases include alpha-amylase derived from a strain of the 8ac///_/s sp. NCIB 12289, NCIB 12512, NCIB 12513 or DSM 9375, all of which are described in detail in WO 95/26397, and the alpha-amylase described by Tsukamoto et al., Biochemical and Biophysical Research Communications, 151 (1988), pp. 25- 31.
  • Other alpha-amylase variants and hybrids are described in WO 96/23874, WO 97/41213, and WO 99/19467.
  • Alpha-amylases derived from a strain of Aspergillus include Aspergillus oryzae and Aspergillus niger alpha-amylases.
  • Commercial alpha-amylase products and products containing alpha-amylases include TERMAMYLTM SC, FUNGAMYLTM, LIQUOZYMETM and SANTM SUPER.
  • Fungal alpha-amylases may be added in an amount of 0.001-1.0 AFAU/g DS, preferably from 0.002-0.5 AFAU/g DS, preferably 0.02-0.1 AFAU/g DS.
  • Bacillus alpha- amylases may be added in effective amounts well known to the person skilled in the art.
  • Saccharification and Fermentation To produce low molecular sugars DP 1-3 (i.e., carbohydrate source) that can be metabolized by a fermenting organism, such as, yeast, the maltodexthn from the liquefaction step must be further hydrolyzed in a saccharification step.
  • the hydrolysis is preferably performed enzymatically using a carbohydrate-source generating enzyme, such as preferably glucoamylase.
  • a carbohydrate-source generating enzyme such as preferably glucoamylase.
  • alpha-glucosidases, beta-amylase or acid alpha-amylases may be used.
  • the saccharification and fermentation may be carried out simultaneously (SSF process).
  • the combined saccharification and fermentation process may be carried out as defined above in the presence of a glucoamylase derived from a microorganism or a plant.
  • Suitable carbohydrate-source generating enzymes such as glucoamylases, include the one listed. Carbohydrate-source generating enzymes and concentrations of use are described in the "Carbohydrate-Source Generating Enzyme"-section above.
  • Glucoamylases may in an embodiment be added in an amount of 0.02-2 AGU/g DS, preferably 0.1-1 AGU/g DS, such as 0.2 AGU/g DS.
  • the ratio between acidic fungal alpha- amylase activity (AFAU) per glucoamylase activity (AGU) (AFAU per AGU) may in one embodiment be at least 0.1 , preferably, at least 0.16, such as in the range from 0.12 to 0.30.
  • the fermenting organism is in one embodiment be a yeast, preferably one of the yeast mentioned in the Fermenting organisms" section above.
  • the fermentation step may be in accordance with the fermentation process of the invention.
  • the fermenting organism is preferably yeast, which is applied to the mash.
  • Preferred yeast is derived from Saccharomyces spp., more preferably, from Saccharomyces cerevisiae.
  • yeast is applied to the mash and the fermentation is ongoing for 24-96 hours, such as typically 35-60 hours.
  • the temperature is generally between 26-34°C, in particular about 32°C
  • the pH is generally from pH 3-6, preferably around pH 4-5.
  • Yeast cells are preferably applied in amounts of 10 5 to 10 12 , preferably from 10 7 to 10 10 , especially 5x10 7 viable yeast count per ml of fermentation broth. During the ethanol producing phase the yeast cell count should preferably be in the range from 10 7 to 10 10 , especially around 2 x 10 8 . Further guidance in respect of using yeast for fermentation can be found in, e.g., "The alcohol Textbook” (Editors K. Jacques, T.P. Lyons and D.R.Kelsall, Nottingham University Press, United Kingdom 1999), which is hereby incorporated by reference.
  • the fermented mash is distilled using any method know in the art.
  • the mash may be distilled to extract the fermentation product, in particular ethanol.
  • the end product, obtained according to an ethanol production process of the invention may be used as, e.g., fuel ethanol; drinking ethanol, i.e., potable neutral spirits; or industrial ethanol. Further details on how to carry out milling, liquefaction, saccharification, fermentation, distillation, and ethanol recovery are well known to the skilled person.
  • Glucoamylase SF Balanced blend of Aspergillus niger glucoamylase and A. niger acid alpha-amylase having a ratio between AGU and AFAU of approx. 9:1.
  • Red Star available from Red Star/Lesaffre, USA
  • Alpha-amylase activity may be determined using potato starch as substrate. This method is based on the break-down of modified potato starch by the enzyme, and the reaction is followed by mixing samples of the starch/enzyme solution with an iodine solution. Initially, a blackish-blue color is formed, but during the break-down of the starch the blue color gets weaker and gradually turns into a reddish-brown, which is compared to a colored glass standard.
  • KNU Kilo Novo alpha amylase Unit
  • FAU Fungal Alpha-Amylase Unit
  • AMG 300 L from Novozymes A/S, Denmark, glucoamylase wild-type Aspergillus niger G , also disclosed in Boel et al.
  • the neutral alpha-amylase in this AMG falls after storage at room temperature for 3 weeks from approx. 1 FAU/mL to below 0.05 FAU/mL.
  • the acid alpha-amylase activity in this AMG standard is determined in accordance with the following description. In this method, 1 AFAU is defined as the amount of enzyme, which degrades 5.260 mg starch dry matter per hour under standard conditions. Iodine forms a blue complex with starch but not with its degradation products. The intensity of colour is therefore directly proportional to the concentration of starch.
  • Amylase activity is determined using reverse colorimetry as a reduction in the concentration of starch under specified analytic conditions.
  • Acid Alpha-amylase Units The acid alpha-amylase activity can be measured in AAU (Acid Alpha-amylase
  • One Acid Amylase Unit is the quantity of enzyme converting 1 g of starch (100% of dry matter) per hour under standardized conditions into a product having a transmission at 620 nm after reaction with an iodine solution of known strength equal to the one of a color reference.
  • the starch should be Lintner starch, which is a thin-boiling starch used in the laboratory as colorimetric indicator. Lintner starch is obtained by dilute hydrochloric acid treatment of native starch so that it retains the ability to color blue with iodine. Further details can be found in EP 0140410, which disclosure is hereby incorporated by reference.
  • Glucoamylase activity (AGP Glucoamylase (equivalent to amyloglucosidase) converts starch into glucose.
  • the amount of glucose is determined here by the glucose oxidase method for the activity determination. The method described in the section 76-11 Starch — Glucoamylase Method with Subsequent Measurement of Glucose with Glucose Oxidase in "Approved methods of the American Association of Cereal Chemists". Vol.1-2 AACC, from American Association of Cereal Chemists, (2000); ISBN: 1-891127-12-8.
  • One glucoamylase unit is the quantity of enzyme which will form 1 micromol of glucose per minute under the standard conditions of the method. Standard conditions/reaction conditions:
  • the starch should be Lintner starch, which is a thin-boiling starch used in the laboratory as colorimetric indicator. Lintner starch is obtained by dilute hydrochloric acid treatment of native starch so that it retains the ability to color blue with iodine.
  • AGU The Novo Glucoamylase Activity
  • AGU The Novo Glucoamylase Unit (AGU) is defined as the amount of enzyme, which hydrolyzes 1 micromole maltose per minute under the standard conditions 37°C, pH 4.3, substrate: maltose 23.2 mM, buffer: acetate 0.1 M, reaction time 5 minutes.
  • An autoanalyzer system may be used. Mutarotase is added to the glucose dehydrogenase reagent so that any alpha-D-glucose present is turned into beta-D-glucose.
  • Glucose dehydrogenase reacts specifically with beta-D-glucose in the reaction mentioned above, forming NADH which is determined using a photometer at 340 nm as a measure of the original glucose concentration.
  • polypeptide "homology” is understood as the degree of "identity" between two sequences indicating a derivation of the first sequence from the second.
  • the homology may suitably be determined by means of computer programs known in the art such as GAP provided in the GCG program package (Program Manual for the Wisconsin Package, Version 8, August 1994, Genetics Computer Group, 575 Science Drive, Madison, Wisconsin, USA 53711 ) (Needleman, S.B. and Wunsch, CD., (1970), Journal of Molecular Biology, 48, 443-453. The following settings for amino acid sequence comparison are used: GAP creation penalty of 3.0 and GAP extension penalty of 0.1.
  • Example 1 Delayed release of glucose during SSF The experiment was carried out in 500 ml shake flasks as triplicates. Enzyme additions were dosed at different time points to examine the effect of a delayed release of glucose. Two different experiments were carried out. The first experiment investigated the impact from delaying the enzyme addition compared to the time of inoculation of yeast. Table 1 shows the dosing scheme of the experiment. Controls were included in the fermentation to have a reference yield from a standard fermentation with simultaneous yeast and enzyme addition.
  • Table 1 Delayed dosing of enzyme. Table shows time points of enzyme addition and added amounts in percent of the total dose. Exp lD Time [h] Total # 0 8 24 Dose I 100% 0% 0% 100% II 0% 100% 0% 100% III 0% 0% 100% 100% The second experiment looked at distributing the enzyme dose addition over 24 hours. A small percentage of the total dose was added up front to provide low levels of available substrate in the beginning of the fermentation where the yeast cells are in the lag phase. Table 2 shows the dosing scheme where the initial addition ranges from 1% - 20% of the total amount of enzyme added. Also in this experiment, controls were included for a reference yield from a standard fermentation with simultaneous yeast and enzyme addition.
  • Table 2 Gradual Enzyme dosing. Time points and distribution of enzyme dose in percentage of total added. Exp lD Time [h] Total # 0 8 24 Dose A 0% 0% 100% 100% B 1% 0% 99% 100% C 5% 0% 95% 100% D 10% 0% 90% 100% E 20% 0% 80% 100%
  • Table 3 Loading Chart in % w/w-DS for the two conducted shake flask experiments using Glucoamylase SF (GASF) Exp lD O h 8 h 24 h Glucoamy Glucoamy Glucoamy lase SF lase SF lase SF m 1 100 0 0 0.056% - - ⁇ ⁇ II 0 100 0 - 0.056% - III 0 0 0 100 - - 0.056% m A 100 0 0 0.056% - - - ⁇ B 1 0 99 0.001% - 0.055% C 5 0 95 0.003% - 0.053% D
  • Glucoamylase SF (GASF) was added as a total dose of 0.056% w- enzyme/w-DSco m as - Table 3 shows the amounts added in the two experiments at time 0, 8 and 24 hours.
  • GASF Glucoamylase SF
  • Table 3 shows the amounts added in the two experiments at time 0, 8 and 24 hours.
  • penicillin (3 mg/kg), Urea (1 g/kg), and 4 % w/w yeast propagate (overnight culture inoculated from freeze dried yeast cells, RedStar) were added.
  • the enzyme was then added to the bottles according to the pre-determined loading (Table 3) and based on the mash-weight and the determined total solids (TS) content.
  • a Denver DS-IR oven was used to determine the TS-value used for the enzyme addition calculations.
  • the TS was subsequently determined as triplicate measurements after 24 hours drying at 105°C.
  • the bottles were sealed with rubber stoppers and disposable pipettes having a single needle hole to release over pressure. Bottles were placed in 32°C water bath with stirring at 100 rpm and the experiment start time was recorded. Enzyme additions during the fermentation were transferred to the bottles using pipettes. The rubber stopper was loosened and the enzyme added through a crack as small as possible (in order to maintain anaerobic conditions in the bottles). At 65 hours and 135 hours samples were taken for HPLC measurements.
  • Experiment 1 The experiment where the GASF dose was delayed 8 and 24 hours respectively showed that it is possible to control the glycerol-ethanol relationship. From the results in Table 4 it can be seen that the late enzyme addition lowers the relative glycerol production compared to a standard SSF fermentation scheme. Furthermore, the results indicate that a total fermentation time of 65 hours is too short if the GASF is added 24 hours after yeast inoculation. The glycerol/ethanol relationship was lowered from 9% to 8.3%. In comparison most corn based ethanol plants have an approximate glycerol/ethanol relationship of 10 % (w/w).

Abstract

L'invention concerne un procédé de production d'un produit de fermentation, qui comporte les étapes consistant à : introduire l'organisme de fermentation dans le milieu de fermentation ; ajouter ensuite, après la phase de latence dudit organisme, une enzyme produisant des glucides ; et mettre en oeuvre la fermentation dans des conditions permettant de produire le produit de fermentation en question. Cette invention concerne aussi des procédés de production de produits de fermentation comprenant le procédé de l'invention.
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US8372614B2 (en) 2005-02-07 2013-02-12 The United States Of America, As Represented By The Secretary Of Agriculture Ethanol production from solid citrus processing waste
US7879379B1 (en) 2006-11-21 2011-02-01 The United States Of America As Represented By The Secretary Of Agriculture Method of pretreating citrus waste
US8252566B2 (en) * 2008-05-20 2012-08-28 Jj Florida Properties Llc Ethanol production from citrus waste through limonene reduction
MX2010012736A (es) * 2008-05-20 2011-07-20 Jj Florida Properties Llc Eliminacion de compuestos que inhiben fermentacion de desechos citricos utilizando extraccion con solvente y produccion de etanol a partir de desechos citricos.
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